1. 2018 Sv650 Manual
2. 2008 Suzuki Sv650 Specs
3. Suzuki Sv650 Service Manual

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2018 Sv650 Manual

The 1999-2008 Suzuki SV650 sportbike DIY repair manual by Haynes covers:

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• Suzuki SV650, 1999-2008
• Suzuki SV650S, 1999-2008
• Suzuki SV650A/SA, 2007-2008
• Suzuki SV650 Sport, 2008

Note: all models are powered by four-stroke, 90anddeg; V-twin, liquid-cooled, 4-valve per cylinder, 645cc engines.

Book Excerpt: 1999-2008 Suzuki SV650 Sportbike Repair Manual

ENGINE, CLUTCH AND TRANSMISSION

PISTONS

Note: The pistons can be removed with the engine in the frame.

REMOVAL

1. Remove the cylinder block (see Section 15).
2. Before removing the piston from the connecting rods, use a sharp scriber or felt marker pen to write the cylinder identity on the crown of each piston (or on the inside of the skirt if the piston is dirt and going to be cleaned).

   Each piston crown should already have a circular indent on the crown that faces the exhaust side of the cylinder, though the mark may not be visible until the piston is cleaned (see illustration).

   Stuff clean rag around the connecting rod to prevent a dropped circlip falling into the crankcase.

3. Carefully prise out the circlip on one side of the piston using needle nose pliers or a small flat-bladed screwdriver inserted into the notch (see illustration).

   Push the piston pin out from the other side to free the piston from the connecting rod (see illustration). Remove the other circlip and discard them both as new ones must be used.

   When the piston has been removed, slide its pin back into its bore so that the related parts do not get mixed up.

HAYNES HINT: if a piston pin is a tight fit in the piston bosses, soak a rag in boiling water then wring it out and wrap it around the piston- this will expand the alloy piston sufficiently to release its grip on the pin.

If the piston pin is particularly stubborn, extract it using a draw bolt tool, but be careful to protect the piston's working surfaces.

BRAKES, WHEELS AND TIRESBRAKE DISCS: INSPECTION

1. Visually inspect the surface of the disc for score marks and other damage. Light scratches are normal after use and won't affect brake operation, but deep grooves and heavy score marks will reduce braking efficiency and accelerate pas wear. If a disc is badly grooved it must be machined or replaced.
2. To check disc run out, position the bike on an auxiliary stand so that the wheel being checked is off the ground. Mount a dial gauge to a fork slider on the swing arm, according to the wheel , with the plunger on the gauge touching the surface of the disc about 10 mm (1/2in) from the outer edge (see illustration).

   Rotate the wheel and watch the gauge needle, comparing the reading with the limit listed in the Specifications at the beginning of the Chapter. If the run out is greater than the service limit, check the wheel bearings for play (see Chapter 1). If the bearings are worn, replace them (see Section 14) and repeat this check.

   It is also worth removing the disc (see below) and checking for buildup and corrosion (see Step 6) as this will cause run out. If the run out is still excessive, the disc must be replaced, although machining by an engineer may be possible. Note: Always replace the front discs as a pair, never singly.

3. The disc must not be machined or allowed to wear down to a thickness less than the service limit as listed in this Chapter's Specifications and as marked on the disc itself. (see illustrations). Check the thickness of the disc using a micrometer (see illustration). If the thickness of the disc is less than the service limit it must be replaced.

Subject: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008 Suzuki SV650, SV650S, SV650A/SA, SV650 Sport service, maintenance, repair. ISBN-10: 1844257673 ISBN-13: 9781844257676 Haynes 3912

Complete coverage for your vehicle

2008 Suzuki Sv650 Specs

Written from hands-on experience gained from the complete strip-down and rebuild of a Suzuki SV650, Haynes can help you understand, care for and repair your Suzuki SV650. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Suzuki SV650 can help maintain its resale value, save you money, and make it safer to ride.

Online manual

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What's covered

Suzuki SV650, SV650S, SV650SA, and SV650A Haynes Repair Manual Online covering 645cc models for 1999 to 2008

Table of contents

Introduction
Chapter 1: Routine maintenance and servicing
Chapter 2: Engine, clutch and transmission
Chapter 3: Cooling system
Chapter 4: Part A: Fuel and exhaust systems for X,Y, K1 and K2 models
Chapter 4: Part B: Fuel and exhaust systems for K3 models
Chapter 5: Ignition system
Chapter 6: Frame, suspension and final drive
Chapter 7: Brakes, wheels and tires
Chapter 8: Fairing and bodywork
Chapter 9: Electrical system
Wiring diagrams

Online manual

With a Haynes Online Manual in an online format you get all the trusted content of a printed manual, with additional features to help you get the job done. Take your entire manual with you on every journey.

Key features:

Suzuki Sv650 Service Manual

• All colour step-by-step guides for over 200 jobs with 700+ photos
• Image zoom feature for close-up view of jobs
• Brand-new “how to” video tutorials covering key repair tasks
• Print complete sections to take with you into the workshop
• Troubleshooting section – quickly find the cause of a problem
• Colour wiring diagrams help track problems quickly and easily
• Easy search feature – find your job fast
• Dictionary of automotive terms
• Quick links to popular DIY tasks and other jobs linked to your task
• Conversion calculator – imperial and metric units